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Narrator: TODAY ON
"HOW IT'S MADE: DREAM CARS,"
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00:00:02,536 --> 00:00:04,762
THE ALL-NEW JAGUAR XF,
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00:00:04,764 --> 00:00:08,290
A LUXURY SEDAN THAT PROWLS
THE HIGHWAYS IN LAVISH STYLE.
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00:00:08,292 --> 00:00:11,227
-- Captions by VITAC --
www.vitac.com
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00:00:11,229 --> 00:00:14,255
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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JAGUAR HAS BEEN BUILDING CARS
FOR MORE THAN 80 YEARS.
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00:00:27,446 --> 00:00:29,438
IN THE 1950s AND '60s,
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00:00:29,440 --> 00:00:31,573
THEY ESTABLISHED
AN ELEGANT PROFILE
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00:00:31,575 --> 00:00:33,099
FOR THEIR SEDANS,
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00:00:33,101 --> 00:00:37,129
WHICH BECAME THE CARMAKER'S
SIGNATURE STYLE FOR DECADES.
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00:00:37,131 --> 00:00:40,800
IN 2007, THE COMPANY
LAUNCHED THE XF,
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00:00:40,802 --> 00:00:45,455
CREATING A COMPLETELY NEW LOOK
FOR THE 21st CENTURY.
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00:00:45,457 --> 00:00:49,058
THE SECOND-GENERATION XF,
REVEALED IN 2015,
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00:00:49,060 --> 00:00:53,120
IS A COMPLETELY
CLEAN-SHEET DESIGN.
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00:00:53,122 --> 00:00:56,215
THE DIFFERENCES BEGIN
WITH AN ALL-NEW ARCHITECTURE,
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00:00:56,217 --> 00:01:01,738
MADE ALMOST ENTIRELY OF BONDED
AND RIVETED ALUMINUM.
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00:01:01,740 --> 00:01:06,068
THE RESULT IS A LIGHTER,
MORE RIGID CAR.
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00:01:06,070 --> 00:01:07,803
IMPROVED PERFORMANCE ALSO COMES
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00:01:07,805 --> 00:01:12,033
FROM A RANGE OF JAGUAR'S
NEW DIESEL INGENIUM ENGINES.
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00:01:12,035 --> 00:01:14,494
INGENIUM IS A FAMILY OF COMPACT,
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00:01:14,496 --> 00:01:17,697
LIGHTWEIGHT, LOW-EMISSION,
TURBOCHARGED POWER PLANTS
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00:01:17,699 --> 00:01:21,827
BUILT AT JAGUAR LAND ROVER'S
NEW ENGINE MANUFACTURING CENTER.
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00:01:27,117 --> 00:01:28,850
THE BODY OF THE XF STARTS
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WITH NEARLY 20,000 POUNDS
OF COILED SHEET METAL.
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00:01:33,382 --> 00:01:35,774
JAGUAR USES A COMBINATION
OF ALUMINUM
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00:01:35,776 --> 00:01:38,836
AND STEEL TO CREATE
THE XF BODY.
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00:01:38,838 --> 00:01:40,971
WHILE ALUMINUM SAVES WEIGHT,
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00:01:40,973 --> 00:01:45,935
JUDICIOUS USE OF STEEL
IMPROVES WEIGHT DISTRIBUTION.
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00:01:45,937 --> 00:01:48,263
ONCE THE METAL IS CUT
INTO THE REQUIRED SHAPES,
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00:01:48,265 --> 00:01:50,791
AN AUTOMATED SYSTEM
USES SUCTION CUPS
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00:01:50,793 --> 00:01:54,787
TO DESTACK THEM.
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00:01:54,789 --> 00:01:56,722
THE SYSTEM
THEN LOADS THE SHAPES,
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00:01:56,724 --> 00:01:59,283
KNOWN AS BLANKS,
INTO A MASSIVE DIE.
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00:01:59,285 --> 00:02:00,551
THE UPPER SECTION OF THE DIE
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00:02:00,553 --> 00:02:02,419
DESCENDS AND COLD-PRESSES
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00:02:02,421 --> 00:02:05,481
THE METAL TO THE DESIRED
THREE-DIMENSIONAL FORM.
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00:02:05,483 --> 00:02:07,341
THE 110,000-POUND DIE
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CAN PRESS 20 BLANKS
PER MINUTE.
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00:02:15,368 --> 00:02:19,304
THE SECOND OPERATION PERFORMS
THREE FUNCTIONS SIMULTANEOUSLY.
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00:02:19,306 --> 00:02:23,592
IT PIERCES, FOLDS AND TRIMS
THE PANEL TO CREATE THE OPENINGS
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00:02:23,594 --> 00:02:25,760
AND FLANGES
NECESSARY FOR THE PART,
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00:02:25,762 --> 00:02:27,855
WHICH IS A STEEL
INNER DOOR PANEL.
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00:02:31,427 --> 00:02:33,885
THE PRESS LINE
USES LARGE SERVOMOTORS
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00:02:33,887 --> 00:02:38,316
TO PROCESS UP TO
1,200 BLANKS PER HOUR.
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00:02:38,318 --> 00:02:41,177
THIS CUTTING-EDGE TECHNOLOGY
CAN PRODUCE A PANEL
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EVERY THREE SECONDS,
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MAKING IT THE FASTED
STAMPING LINE IN THE WORLD.
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00:02:48,436 --> 00:02:51,304
THE BODY SHOP WHERE THE XF
BEGINS TO TAKE SHAPE
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00:02:51,306 --> 00:02:55,200
IS THE SIZE OF 12
FOOTBALL FIELDS.
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00:02:55,202 --> 00:02:59,130
DESPITE THAT, THE SHOP REQUIRES
ONLY 57 EMPLOYEES
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00:02:59,132 --> 00:03:01,056
BECAUSE THE LINE
IS LARGELY MANNED
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00:03:01,058 --> 00:03:02,925
BY ROBOTS LIKE THIS ONE,
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00:03:02,927 --> 00:03:04,952
WHICH ASSEMBLES THE UNDERFLOOR.
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00:03:07,123 --> 00:03:12,418
BODY-SIDE INNERS GO ON NEXT
AS THE UNDERFLOOR PROCEEDS.
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00:03:12,420 --> 00:03:15,480
ROBOTS WILL JOIN THE METAL
COMPONENTS BY SPOT-WELDING,
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00:03:15,482 --> 00:03:19,009
GLUING, AND RIVETING
THEM TOGETHER.
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00:03:19,011 --> 00:03:21,403
GLUING AND RIVETING
MAKES FOR A POWERFUL,
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00:03:21,405 --> 00:03:23,372
TORSIONALLY RIGID JOINT.
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00:03:25,568 --> 00:03:28,994
IT'S ALSO NECESSARY IN SOME
PLACES BECAUSE, AS NOTED,
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00:03:28,996 --> 00:03:31,630
WHILE THE XF BODY
IS MOSTLY ALUMINUM,
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00:03:31,632 --> 00:03:34,692
SOME OF THE COMPONENTS
ARE MADE OF STEEL.
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00:03:34,694 --> 00:03:36,894
THE TWO METALS CANNOT
BE WELDED TOGETHER
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00:03:36,896 --> 00:03:39,489
AND SO MUST BE JOINED
BY OTHER MEANS.
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00:03:44,321 --> 00:03:47,514
ROBOTS HAVE INSTALLED
THE REAR EXTERIOR PANELING.
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00:03:47,516 --> 00:03:50,242
SPECIAL NOISE-REDUCING PADS
PLACED BETWEEN THE INNER
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00:03:50,244 --> 00:03:52,244
AND OUTER LAYERS
WILL LATER EXPAND
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00:03:52,246 --> 00:03:54,505
IN THE PAINT-SHOP OVENS.
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Narrator: IT'S HARD TO BELIEVE
SUCH A SLEEK OBJECT
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00:04:05,019 --> 00:04:06,686
WAS EVER A BUNCH
OF METAL COMPONENTS
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WAITING TO BE
PUT TOGETHER.
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00:04:10,250 --> 00:04:11,648
IT TAKES A LOT OF PLANNING
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00:04:11,650 --> 00:04:15,145
AND WORK TO MAKE
A JAGUAR XF LOOK SO GOOD.
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00:04:18,708 --> 00:04:21,168
A LIFT ASSIST HOLDS
THE REAR RIGHT-HAND DOOR
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00:04:21,170 --> 00:04:22,302
AT THE CORRECT ANGLE
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00:04:22,304 --> 00:04:25,631
AS A TECHNICIAN GUIDES
IT INTO POSITION.
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00:04:25,633 --> 00:04:32,454
HE USES A HANDHELD DRIVER
TO CONNECT THE HINGES.
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00:04:32,456 --> 00:04:34,456
TEAM MEMBERS GUIDE
THE HOOD INTO PLACE
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00:04:34,458 --> 00:04:37,051
AS THE LIFT ASSIST RESPONDS
TO THE MOVEMENT
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00:04:37,053 --> 00:04:40,913
AND PRESSURE OF THEIR HANDS.
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00:04:40,915 --> 00:04:42,782
THEY HAND-START
THE FASTENER BOLTS
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00:04:42,784 --> 00:04:44,742
TO AVOID CROSS-THREADING THEM.
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00:04:44,744 --> 00:04:47,479
THE DRIVERS THEY USE
ARE DIGITALLY CONNECTED TO
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00:04:47,481 --> 00:04:48,872
A WIRELESS NETWORK,
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00:04:48,874 --> 00:04:51,875
WHICH PROVIDES THE NECESSARY
INFORMATION ABOUT TORQUE
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00:04:51,877 --> 00:04:53,836
WHILE RECORDING
THE OPERATION.
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00:04:57,800 --> 00:05:00,960
A TECHNICIAN MANUALLY
INSTALLS THE RIGHT FRONT FENDER.
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00:05:00,962 --> 00:05:02,628
HE HAND-STARTS THE FASTENERS
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00:05:02,630 --> 00:05:04,897
BECAUSE HE MUST
VERIFY A FLUSH FIT
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00:05:04,899 --> 00:05:06,424
AND CORRECT CAP DISTANCES
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00:05:06,426 --> 00:05:08,760
BEFORE TORQUING THEM
DOWN COMPLETELY.
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00:05:10,956 --> 00:05:12,956
AT THE HIGHLIGHT
INSPECTION STATION,
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00:05:12,958 --> 00:05:15,617
HIGHLY TRAINED TECHNICIANS
WIPE A SPECIAL TEMPORARY
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00:05:15,619 --> 00:05:18,511
COATING ONTO
THE CAR'S SURFACE.
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00:05:18,513 --> 00:05:20,380
THE REFLECTIVITY
OF THE COATING HELPS THEM
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00:05:20,382 --> 00:05:24,443
IDENTIFY ANY IMPERFECTIONS
IN THE METAL.
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00:05:24,445 --> 00:05:26,103
IN ADDITION,
THE VERTICAL STRIP
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00:05:26,105 --> 00:05:28,506
LIGHTING CREATES
A REFLECTIVE PATTERN.
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00:05:28,508 --> 00:05:30,632
ANY DEVIATIONS IN
THE REFLECTIVE PATTERN
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COULD INDICATE A FLAW.
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00:05:36,132 --> 00:05:38,257
THERE ARE TWO
REWORK STATIONS,
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00:05:38,259 --> 00:05:41,727
ONE FOR THE STEEL SECTIONS
AND ONE FOR THE ALUMINUM
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00:05:41,729 --> 00:05:44,055
BECAUSE IF TECHNICIANS
WERE TO USE THE SAME TOOL
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00:05:44,057 --> 00:05:45,323
ON BOTH SURFACES,
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00:05:45,325 --> 00:05:48,452
THE ALUMINUM COULD GET
DAMAGED BY STEEL RESIDUE.
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00:05:53,350 --> 00:05:56,143
ONCE THE REWORK TEAM
HAS FINISHED REMOVING ANY DENTS
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00:05:56,145 --> 00:05:57,544
OR HIGH SPOTS,
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00:05:57,546 --> 00:05:59,338
THE BODY MOVES
TO THE PAINT SHOP,
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00:05:59,340 --> 00:06:01,540
WHERE A TEAM
MEMBER DEGREASES IT.
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00:06:06,473 --> 00:06:08,163
WHILE MUCH OF THE PAINT
SHOP PROCESS
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00:06:08,165 --> 00:06:10,366
IS AUTOMATED,
AT THIS STATION,
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00:06:10,368 --> 00:06:12,493
TECHNICIANS MANUALLY
BRUSH A SEALANT
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00:06:12,495 --> 00:06:14,821
INTO CERTAIN SPECIFIED
JOINTS AND APERTURES
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00:06:14,823 --> 00:06:18,291
ON THE BODY THAT ARE HARD
FOR THE ROBOTS TO REACH.
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00:06:23,249 --> 00:06:25,248
AS THE BODY ENTERS
THIS STATION,
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00:06:25,250 --> 00:06:27,443
A CAMERA TAKES A PICTURE
TO CONFIRM THE CAR
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00:06:27,445 --> 00:06:30,546
MODEL AND ESTABLISH
A LOCATION REFERENCE POINT.
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00:06:34,911 --> 00:06:37,570
NOW THAT THE ROBOTS KNOW
WHICH KIND OF CAR IT IS
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00:06:37,572 --> 00:06:39,464
AND WHERE EXACTLY IT'S LOCATED,
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00:06:39,466 --> 00:06:42,400
THEY CAN GO TO WORK.
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00:06:42,402 --> 00:06:43,727
THEY USE THE SAME SEALANT
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00:06:43,729 --> 00:06:46,063
AS THE TECHNICIANS
AT THE PREVIOUS STATION,
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00:06:46,065 --> 00:06:48,523
APPLYING A THICK BEAD
OVER EVERY JOINT
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00:06:48,525 --> 00:06:50,993
TO ENSURE NO WATER
CAN PENETRATE.
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00:06:56,184 --> 00:06:59,251
BELL-SHAPED NOZZLES
SPRAY PRIMER.
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00:06:59,253 --> 00:07:01,411
THE PAINT CONTAINS
A POSITIVE CHARGE
126
00:07:01,413 --> 00:07:04,073
TO ADHERE TO THE NEGATIVELY
CHARGED ELECTROCOAT
127
00:07:04,075 --> 00:07:07,936
TO ENSURE MAXIMUM COVERAGE
AND MINIMAL WASTE.
128
00:07:07,938 --> 00:07:10,204
JAGUAR USES A PRIMER PIGMENTED
129
00:07:10,206 --> 00:07:12,532
TO MATCH THE FINAL
COLOR OF THE CAR.
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00:07:15,070 --> 00:07:18,496
PAINT EXPERTS PRIME
THE INTERIOR MANUALLY.
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00:07:18,498 --> 00:07:22,693
THEN THE CAR MOVES
TO THE BASE-COAT ROBOT BOOTH.
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00:07:22,695 --> 00:07:25,621
HERE, ROBOTS EQUIPPED
WITH MULTIPLE NOZZLE HEADS
133
00:07:25,623 --> 00:07:28,749
COVER THE CAR
WITH ITS BASE COAT.
134
00:07:28,751 --> 00:07:32,286
INTERESTINGLY, WHITE IS ONE
OF THE MOST POPULAR CHOICES.
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00:07:32,288 --> 00:07:34,647
HOWEVER, THE ROBOTS
CAN PURGE A COLOR
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00:07:34,649 --> 00:07:36,483
IN JUST 8 SECONDS.
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00:07:39,313 --> 00:07:42,172
THAT MEANS AS DIFFERENT
COLOR CARS COME THROUGH,
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00:07:42,174 --> 00:07:44,767
THERE'S NO NEED TO PAUSE
BETWEEN COLORS.
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00:07:47,237 --> 00:07:49,063
AFTER THE BASE COAT GOES ON,
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00:07:49,065 --> 00:07:50,597
THE CAR HEADS FOR A STINT
141
00:07:50,599 --> 00:07:52,333
IN THE OVEN
TO CURE THE PAINT
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00:07:52,335 --> 00:07:55,394
BEFORE RECEIVING
A PROTECTIVE CLEAR COAT.
143
00:07:55,396 --> 00:07:58,790
WHILE IN THE OVEN, THE SPECIAL
NOISE-REDUCING PADS AND BAFFLES
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00:07:58,792 --> 00:08:01,918
POSITIONED BETWEEN THE INNER
AND OUTER SKIN OF THE CAR
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00:08:01,920 --> 00:08:04,120
WILL EXPAND IN PLACE.
146
00:08:07,551 --> 00:08:08,750
IN THE INSPECTION AREA,
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00:08:08,752 --> 00:08:11,278
THE CAR MOVES THROUGH
DIFFERENT STATIONS
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00:08:11,280 --> 00:08:13,012
WHERE INSPECTORS FOCUS
ON EXAMINING
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00:08:13,014 --> 00:08:15,206
A PARTICULAR PART OF THE CAR.
150
00:08:15,208 --> 00:08:17,835
TECHNICIANS QUICKLY CORRECT
ANY IMPERFECTIONS.
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00:08:30,234 --> 00:08:33,627
Narrator: THIS VIEW OF JAGUAR
LAND ROVER'S NEW INGENIUM ENGINE
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00:08:33,629 --> 00:08:36,422
IS ON DISPLAY
IN THE POWERTRAIN WAY ATRIUM
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00:08:36,424 --> 00:08:39,292
OF THE COMPANY'S
ENGINE MANUFACTURING CENTER.
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00:08:39,294 --> 00:08:41,585
IT WAS CREATED FOR
THE QUEEN'S CEREMONIAL
155
00:08:41,587 --> 00:08:44,581
OPENING OF THE FACILITY IN 2014.
156
00:08:46,985 --> 00:08:48,844
AN AUTOMATED SYSTEM
LOADS THE ROUGH
157
00:08:48,846 --> 00:08:51,780
FORGING OF THE STEEL CRANK
INTO A MILLING MACHINE
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00:08:51,782 --> 00:08:56,702
THAT WILL COMPLETE
THE FIRST OF TWO OPERATIONS.
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00:08:56,704 --> 00:08:59,571
THIS MACHINE USES HIGH-SPEED
CARBIDE-TIPPED TOOLS
160
00:08:59,573 --> 00:09:04,160
TO CUT THE CRANK DOWN
TO ITS APPROXIMATE SHAPE.
161
00:09:04,162 --> 00:09:05,794
THIS MEANS THE MACHINE REMOVES
162
00:09:05,796 --> 00:09:09,323
METAL BUT DOESN'T
FINISH THE SURFACES.
163
00:09:09,325 --> 00:09:12,786
THIS PROCESS IS
HIGH-PRECISION WORK.
164
00:09:12,788 --> 00:09:14,320
THE MACHINE BRINGS THE SURFACES
165
00:09:14,322 --> 00:09:19,284
TO WITHIN 250 MICRONS
OF THEIR FINISHED PARAMETERS.
166
00:09:19,286 --> 00:09:21,411
A SET OF CLAMPS
REPOSITION THEMSELVES
167
00:09:21,413 --> 00:09:23,680
WITH THE MILLING TOOLS
TO PREVENT THE CRANK
168
00:09:23,682 --> 00:09:26,875
FROM BOWING UNDER PRESSURE
FROM THE LOAD BEING APPLIED.
169
00:09:34,102 --> 00:09:36,101
A GANTRY LOADER TRANSFERS
THE CRANK
170
00:09:36,103 --> 00:09:38,162
TO THIS FINISHING STATION.
171
00:09:38,164 --> 00:09:41,358
HERE, MULTIPLE ARMS EQUIPPED
WITH FINE EMERY PAPER
172
00:09:41,360 --> 00:09:44,894
CLOSE AROUND THE CRANK
AND BEGIN POLISHING.
173
00:09:44,896 --> 00:09:48,890
THE MACHINE SPINS
THE CRANK UP TO 100 RPM
174
00:09:48,892 --> 00:09:53,779
WHILE SIMULTANEOUSLY CREATING
180 OSCILLATIONS PER SECOND.
175
00:09:53,781 --> 00:09:55,847
HYDRAULIC OIL FLOWS
CONTINUOUSLY,
176
00:09:55,849 --> 00:09:57,708
CLEANING GRIT FROM THE PAPER
177
00:09:57,710 --> 00:10:00,211
TO ENSURE THE PROCESS
RUNS SMOOTHLY.
178
00:10:02,240 --> 00:10:04,106
A TECHNICIAN USES A LIFT ASSIST
179
00:10:04,108 --> 00:10:07,534
TO LOAD THE CRANK
INTO THE CRANKCASE.
180
00:10:07,536 --> 00:10:10,530
THIS STATION IS IN THE FIRST
OF 17 ZONES
181
00:10:10,532 --> 00:10:12,465
IN THE DIESEL ASSEMBLY HALL.
182
00:10:15,261 --> 00:10:17,129
TWO ROBOTS WORK IN UNISON.
183
00:10:17,131 --> 00:10:19,323
WHILE ON LIFTS AND LOADS
THE ENGINE BLOCKS
184
00:10:19,325 --> 00:10:20,791
INTO A LOCATOR DEVICE,
185
00:10:20,793 --> 00:10:24,420
THE SECOND BRINGS PISTONS
INTO STUFFING POSITION.
186
00:10:24,422 --> 00:10:27,148
THE LOADING DEVICE THEN GRIPS
THE TOP OF THE PISTON
187
00:10:27,150 --> 00:10:30,143
AND COMPRESSES ITS PISTON
RINGS BEFORE INSERTING.
188
00:10:33,147 --> 00:10:35,473
THERE ARE TWO PISTON
LOAD STATIONS.
189
00:10:35,475 --> 00:10:37,675
EACH ONE IS RESPONSIBLE
FOR INSTALLING TWO
190
00:10:37,677 --> 00:10:39,836
OF THE ENGINE'S FOUR PISTONS.
191
00:10:43,967 --> 00:10:45,833
A TECHNICIAN BRINGS
THE CYLINDER HEAD
192
00:10:45,835 --> 00:10:48,428
TO THE ENGINE BLOCK.
193
00:10:48,430 --> 00:10:50,030
WITH THE HELP
OF LOCATOR PINS,
194
00:10:50,032 --> 00:10:52,725
HE ALIGNS AND LOWERS
IT INTO PLACE.
195
00:10:56,455 --> 00:10:58,122
TEAM MEMBERS LOAD
THE CAM CARRIER
196
00:10:58,124 --> 00:11:00,049
SUBASSEMBLY INTO POSITION.
197
00:11:00,051 --> 00:11:01,450
LIKE OTHER COMPONENTS,
198
00:11:01,452 --> 00:11:04,979
THIS CAN DIFFER
FROM ENGINE TO ENGINE.
199
00:11:04,981 --> 00:11:07,073
THIS PRODUCTION LINE
IS SO FLEXIBLE
200
00:11:07,075 --> 00:11:09,509
THAT IT CAN PRODUCE UP
TO 28 DIFFERENT DERIVATIVES
201
00:11:09,511 --> 00:11:11,603
OF THE INGENIUM
AT THE SAME TIME.
202
00:11:16,201 --> 00:11:18,935
A TECHNICIAN INSTALLS INJECTORS.
203
00:11:18,937 --> 00:11:23,331
DIFFERENT ENGINE DERIVATIVES
CAN REQUIRE DIFFERENT INJECTORS.
204
00:11:23,333 --> 00:11:25,593
AN AUTOMATED SYSTEM
ENSURES HE IS POSITIONING
205
00:11:25,595 --> 00:11:28,387
THE CORRECT INJECTORS
IN THE RIGHT ENGINE.
206
00:11:28,389 --> 00:11:30,389
HE SCANS THEIR
TWO DIMENSIONAL CODES
207
00:11:30,391 --> 00:11:33,083
TO VERIFY THE INSTALLATION.
208
00:11:33,085 --> 00:11:37,413
A CAMERA WILL VERIFY
THE ASSEMBLY TO TRIPLE-CHECK.
209
00:11:37,415 --> 00:11:40,408
AT THE NEXT STATION, A TEAM
MEMBER INSTALLS THE CLAMPS
210
00:11:40,410 --> 00:11:42,477
THAT HOLD THE INJECTORS
IN PLACE.
211
00:11:44,540 --> 00:11:45,939
HE RUNS DOWN THE BOLTS
212
00:11:45,941 --> 00:11:47,874
WITH A DIGITALLY
CONTROLLED DRIVER
213
00:11:47,876 --> 00:11:49,568
THAT MONITORS THE ANGLE TRAVELED
214
00:11:49,570 --> 00:11:51,503
BY THE FASTENER
AND THE TORQUE,
215
00:11:51,505 --> 00:11:54,198
WHICH MUST FALL WITHIN
A SPECIFIED WINDOW.
216
00:12:00,231 --> 00:12:02,423
A TECHNICIAN POSITIONS
A GUIDE PIN,
217
00:12:02,425 --> 00:12:06,318
WHICH HELPS HIM LOCATE
THE HIGH-PRESSURE FUEL RAIL.
218
00:12:06,320 --> 00:12:09,581
THE TORQUE SEQUENCE
IS CRUCIAL HERE.
219
00:12:09,583 --> 00:12:11,850
AFTER RUNNING DOWN
EACH OF THE TWO BOLTS,
220
00:12:11,852 --> 00:12:16,179
THE TOOL AUTOMATICALLY BACKS
THEM OFF A QUARTER TURN.
221
00:12:16,181 --> 00:12:18,841
THIS IS BECAUSE THEY CAN'T BE
TIGHTENED DOWN FULLY
222
00:12:18,843 --> 00:12:21,569
UNTIL THE HIGH-PRESSURE
PIPES ARE INSTALLED.
223
00:12:24,741 --> 00:12:26,065
AT THE NEXT STATION,
224
00:12:26,067 --> 00:12:29,126
A TEAM MEMBER POSITIONS
THE FOUR HIGH-PRESSURE PIPES
225
00:12:29,128 --> 00:12:32,530
AND FINGER-TIGHTENS
THEIR FASTENERS.
226
00:12:32,532 --> 00:12:37,552
THE PIPES CARRY FUEL
FROM THE RAIL TO THE INJECTORS.
227
00:12:37,554 --> 00:12:39,087
IN SOME OF
THE DIESEL ENGINES,
228
00:12:39,089 --> 00:12:42,816
THE PRESSURE CAN BE AS HIGH
AS 26 POUNDS PER SQUARE INCH.
229
00:12:47,814 --> 00:12:50,074
BECAUSE THE USUAL TORQUE
TOOLS CAN'T ACCESS
230
00:12:50,076 --> 00:12:51,609
THE NUTS ON THE PIPES,
231
00:12:51,611 --> 00:12:53,343
A TECHNICIAN USES
AN OPEN WRENCH
232
00:12:53,345 --> 00:12:57,039
TO TIGHTEN THE FASTENERS
TO THE REQUIRED PARAMETERS.
233
00:12:57,041 --> 00:13:00,434
THESE TOOLS USE BLUETOOTH
TECHNOLOGY TO COMMUNICATE
234
00:13:00,436 --> 00:13:02,462
WITH THE PRODUCTION
CONTROL SYSTEM.
235
00:13:04,766 --> 00:13:06,825
HERE, NEARING COMPLETION,
236
00:13:06,827 --> 00:13:09,427
THE ENGINE HAS BEEN EQUIPPED
WITH ITS WIRING HARNESS
237
00:13:09,429 --> 00:13:11,788
AND HEADS FOR THE INLINE
TESTING STATION
238
00:13:11,790 --> 00:13:13,724
ON A RAIL TRANSPORT SYSTEM.
239
00:13:18,055 --> 00:13:20,380
THE TESTING STATION
CAN ACCOMMODATE THREE ENGINES
240
00:13:20,382 --> 00:13:23,108
AT A TIME.
241
00:13:23,110 --> 00:13:24,911
WHILE THE SYSTEM
TESTS ONE ENGINE,
242
00:13:24,913 --> 00:13:28,473
A TECHNICIAN PREPARES A SECOND
AND FINISHES OFF A THIRD.
243
00:13:31,403 --> 00:13:33,002
THE SYSTEM PLUGS
AN ELECTRIC MOTOR
244
00:13:33,004 --> 00:13:34,403
INTO THE TRANSMISSION
245
00:13:34,405 --> 00:13:37,265
AND SPINS THE ENGINE
UP TO 3,000 RPM
246
00:13:37,267 --> 00:13:38,992
WHILE CHECKING DOZENS
OF PARAMETERS
247
00:13:38,994 --> 00:13:41,662
IN JUST 90 SECONDS.
248
00:13:44,659 --> 00:13:46,325
ONCE THE ENGINE MANUFACTURING
249
00:13:46,327 --> 00:13:48,485
CENTER HAS FINISHED
BUILDING AN ENGINE,
250
00:13:48,487 --> 00:13:51,214
IT COMES HERE TO
THE POWERTRAIN ASSEMBLY LINE
251
00:13:51,216 --> 00:13:53,682
WHERE TEAM MEMBERS LOWER IT
ONTO A FRONT AXLE
252
00:13:53,684 --> 00:13:55,643
AND FASTEN IT IN PLACE.
253
00:13:57,881 --> 00:14:00,806
FOR THE REAR-WHEEL-DRIVE XF,
254
00:14:00,808 --> 00:14:03,368
THEY INSTALL THIS 2-LITER
FOUR-CYLINDER ENGINE
255
00:14:03,370 --> 00:14:05,504
IN A NORTH-SOUTH ORIENTATION.
256
00:14:08,700 --> 00:14:11,426
TECHNICIANS THEN POSITION
AND ATTACH THE COOLANT PACK,
257
00:14:11,428 --> 00:14:14,896
INCLUDING THE MAIN RADIATOR.
258
00:14:14,898 --> 00:14:16,690
THE LIGHTWEIGHT COMPONENT
MAKES GOOD USE
259
00:14:16,692 --> 00:14:18,959
OF ALUMINUM'S THERMAL
CONDUCTION PROPERTIES
260
00:14:18,961 --> 00:14:20,853
TO HELP REMOVE HEAT
FROM THE ENGINE
261
00:14:20,855 --> 00:14:22,955
AS EFFICIENTLY AS POSSIBLE.
262
00:14:32,797 --> 00:14:34,722
Narrator: WHETHER YOU'RE LOOKING
UNDER THE HOOD
263
00:14:34,724 --> 00:14:37,190
OR SITTING INSIDE
ITS LUXURIOUS COCKPIT,
264
00:14:37,192 --> 00:14:42,180
THE JAGUAR XF PRESENTS SLEEK
FINISHED LINES AND SURFACES.
265
00:14:42,182 --> 00:14:44,849
BUT GETTING IT TO THIS
POINT REQUIRES A PRECISE
266
00:14:44,851 --> 00:14:46,776
AND EFFICIENT PRODUCTION LINE.
267
00:14:48,813 --> 00:14:50,806
HERE ON THE GENERAL
ASSEMBLY LINE,
268
00:14:50,808 --> 00:14:53,541
TEAM MEMBERS BRING
THE WIRING HARNESS TO THE CAR
269
00:14:53,543 --> 00:14:56,704
WITH THE HELP OF A SPECIALIZED
LIFT-ASSIST DEVICE.
270
00:14:59,533 --> 00:15:02,693
THE HARNESS HAS BEEN HEATED
TO HELP MAKE IT MALLEABLE ENOUGH
271
00:15:02,695 --> 00:15:04,362
TO TUCK EASILY
INTO THE CORNERS
272
00:15:04,364 --> 00:15:07,556
AND CREVICES
OF THE CAR'S INTERIOR.
273
00:15:07,558 --> 00:15:10,760
THE FOUR-MAN TEAM
HAS JUST 190 SECONDS
274
00:15:10,762 --> 00:15:14,622
TO FULLY INSTALL THE HARNESS.
275
00:15:14,624 --> 00:15:16,683
EACH HARNESS IS
COMPLETELY CUSTOMIZED
276
00:15:16,685 --> 00:15:18,285
TO MEET THE PRECISE PARAMETERS
277
00:15:18,287 --> 00:15:20,245
REQUESTED BY THE CLIENT.
278
00:15:25,978 --> 00:15:27,503
ONE OF THE MANY
FEATURES CUSTOMERS
279
00:15:27,505 --> 00:15:31,432
CAN CHOOSE IS
A PANORAMIC GLASS ROOF.
280
00:15:31,434 --> 00:15:33,701
HERE, A ROBOT BRINGS THE GLASS
281
00:15:33,703 --> 00:15:37,196
TO A DEVICE
WHICH CENTERS IT PERFECTLY.
282
00:15:37,198 --> 00:15:39,557
THIS IS CRUCIAL TO ENSURING
THE INSTALLATION
283
00:15:39,559 --> 00:15:40,825
WILL BE FLAWLESS.
284
00:15:44,523 --> 00:15:47,457
A ROBOT THEN TRANSFERS
THE GLASS TO A MACHINE
285
00:15:47,459 --> 00:15:50,251
WHICH APPLIES A THICK BEAD
OF POLYURETHANE ADHESIVE
286
00:15:50,253 --> 00:15:54,148
DESIGNED TO BOND
DISSIMILAR MATERIALS.
287
00:15:54,150 --> 00:15:58,077
HERE, IT MUST BOND
GLASS TO METAL.
288
00:15:58,079 --> 00:16:01,872
TEAM MEMBERS GUIDE
AN ASSISTER DOWN INTO PLACE.
289
00:16:01,874 --> 00:16:03,407
LOCATION PINS ON THE GLASS
290
00:16:03,409 --> 00:16:05,601
FIT INTO HOLES
IN THE ROOF FRAME,
291
00:16:05,603 --> 00:16:08,896
ENSURING PRECISE INSTALLATION.
292
00:16:08,898 --> 00:16:12,225
THE ASSISTER APPLIES PRECISELY
DESIGNATED AMOUNT OF FORCE
293
00:16:12,227 --> 00:16:13,894
TO FIX IT IN PLACE.
294
00:16:18,025 --> 00:16:20,091
A THREE-PART JIG HELPS
THE TECHNICIAN
295
00:16:20,093 --> 00:16:22,485
INSTALL ALL OF
THE NECESSARY BADGES,
296
00:16:22,487 --> 00:16:24,713
INCLUDING THE FAMOUS
JAGUAR SYMBOL
297
00:16:24,715 --> 00:16:26,582
AND THE LEGENDARY NAME.
298
00:16:28,978 --> 00:16:32,646
THE XF's BATTERY SITS
IN A WELL UNDER THE TRUNK.
299
00:16:32,648 --> 00:16:33,840
IT'S POSITIONED BACK HERE
300
00:16:33,842 --> 00:16:36,309
TO IMPROVE THE CAR'S
WEIGHT DISTRIBUTION.
301
00:16:38,504 --> 00:16:39,771
CAREFULLY
DISTRIBUTING THE WEIGHT
302
00:16:39,773 --> 00:16:41,131
THROUGHOUT A CAR HELPS
303
00:16:41,133 --> 00:16:43,400
TO IMPROVE ITS DYNAMIC HANDLING.
304
00:16:47,798 --> 00:16:50,256
WITH THE HELP OF
A SPECIALIZED LIFT ASSIST,
305
00:16:50,258 --> 00:16:53,919
TEAM MEMBERS
INSTALL A DASHBOARD.
306
00:16:53,921 --> 00:16:56,788
CONTAINING THE INSTRUMENT PANELS
AND THE ENTERTAINMENT INTERFACE,
307
00:16:56,790 --> 00:16:59,082
THIS ELEMENT
OF THE CAR'S INTERIOR
308
00:16:59,084 --> 00:17:02,512
HAS BEEN UPHOLSTERED TO THE
CLIENT'S SPECS BY A SUPPLIER.
309
00:17:05,742 --> 00:17:07,675
TECHNICIANS
POSITION THE WINDSHIELD
310
00:17:07,677 --> 00:17:09,343
FOLLOWING A SIMILAR PROCEDURE
311
00:17:09,345 --> 00:17:13,732
TO THE INSTALLATION
OF THE PANORAMIC ROOF.
312
00:17:13,734 --> 00:17:15,000
THE RAISED HOOD ENSURES
313
00:17:15,002 --> 00:17:17,002
THAT TEAM MEMBERS
CAN PLACE THE GLASS
314
00:17:17,004 --> 00:17:19,162
WITHOUT DRAGGING THE BEAD
OF ADHESIVE
315
00:17:19,164 --> 00:17:21,698
OVER THE FRAME
AS THEY DO SO.
316
00:17:21,700 --> 00:17:25,027
THEY THEN TAP
THE GLASS FIRMLY IN PLACE.
317
00:17:29,025 --> 00:17:30,416
ON THE POWERTRAIN LINE,
318
00:17:30,418 --> 00:17:32,418
A TECHNICIAN LOWERS
THE REAR AXLE,
319
00:17:32,420 --> 00:17:36,448
SUBFRAME, AND PROP SHAFT
ONTO A VERY COMPLEX JIG,
320
00:17:36,450 --> 00:17:39,442
WHICH WILL EVENTUALLY HOLD ALL
THE ELEMENTS OF THE POWERTRAIN
321
00:17:39,444 --> 00:17:41,678
DURING THE SUBASSEMBLY PROCESS.
322
00:17:46,043 --> 00:17:48,502
AS THE JIG ADVANCES
DOWN THE LINE,
323
00:17:48,504 --> 00:17:50,562
IT PAUSES WHEN IT MEETS
A CONVEYOR SYSTEM
324
00:17:50,564 --> 00:17:52,798
CARRYING THE ENGINE.
325
00:17:52,800 --> 00:17:54,658
THE AUTOMATED SYSTEM
LOADS THE ENGINE
326
00:17:54,660 --> 00:17:57,928
ONTO THE POWERTRAIN JIG.
327
00:17:57,930 --> 00:18:00,256
THE JIG THEN PROCEEDS
TO THE NEXT STATION,
328
00:18:00,258 --> 00:18:02,751
WHERE IT WILL MARRY
WITH THE XF BODY.
329
00:18:08,016 --> 00:18:11,275
THE MARRIAGE IS ALSO
FULLY AUTOMATED.
330
00:18:11,277 --> 00:18:14,012
THE POWERTRAIN SLIDES
IN UNDERNEATH THE BODY,
331
00:18:14,014 --> 00:18:17,141
WHICH IS SUSPENDED
FROM AN OVERHEAD TRACK.
332
00:18:17,143 --> 00:18:20,835
PRECISION LASERS ALIGN
THE TWO ASSEMBLIES PERFECTLY.
333
00:18:20,837 --> 00:18:24,097
SENSORS KEEP TRACK OF
THE OPERATION'S PROGRESS.
334
00:18:24,099 --> 00:18:25,832
AND IF ANYTHING
IS OUT OF ALIGNMENT,
335
00:18:25,834 --> 00:18:27,694
THEY WILL HALT THE PROCEDURE.
336
00:18:31,099 --> 00:18:34,225
SIX ROBOTS SEND DRIVERS
UP THROUGH THE SUBFRAME
337
00:18:34,227 --> 00:18:38,021
ASSEMBLY AND ATTACH IT
SECURELY TO THE BODY.
338
00:18:38,023 --> 00:18:40,982
IF THE ROBOTS FAIL
TO ACHIEVE THE CORRECT TORQUE,
339
00:18:40,984 --> 00:18:42,651
EVERYTHING WILL
AUTOMATICALLY STOP
340
00:18:42,653 --> 00:18:44,645
UNTIL THE PROBLEM IS CORRECTED.
341
00:18:49,110 --> 00:18:50,976
WHILE THE CAR IS STILL ELEVATED,
342
00:18:50,978 --> 00:18:52,970
TEAM MEMBERS PERFORM
THE NEXT OPERATION
343
00:18:52,972 --> 00:18:56,632
OF INSTALLING THE FINAL
SILENCERS AND TAILPIPES.
344
00:18:58,336 --> 00:19:00,661
THERE ARE 16 DIFFERENT
POSSIBLE DERIVATIVES
345
00:19:00,663 --> 00:19:02,130
FOR THE EXHAUST SYSTEM,
346
00:19:02,132 --> 00:19:05,992
DEPENDING ON THE TYPE OF ENGINE
CHOSEN BY THE CUSTOMER.
347
00:19:05,994 --> 00:19:08,261
THE TECHNICIANS USE
THE JIG ATTACHMENT
348
00:19:08,263 --> 00:19:12,190
TO ENSURE THE TAILPIPES
ARE PERFECTLY SITUATED.
349
00:19:12,192 --> 00:19:14,484
THIS IS NOT ONLY A MATTER
OF AESTHETIC BALANCE,
350
00:19:14,486 --> 00:19:17,412
BUT ALSO OF PRACTICALITY.
351
00:19:17,414 --> 00:19:19,681
THE TAILPIPES MUST BE
CORRECTLY POSITIONED
352
00:19:19,683 --> 00:19:21,776
FOR THE REAR BUMPER
TO FIT OVER THEM.
353
00:19:28,869 --> 00:19:31,336
THE BUMPERS ARE MADE
OF A PLASTIC COMPOSITE,
354
00:19:31,338 --> 00:19:33,563
A LIGHTWEIGHT MATERIAL
THAT CAN BE REPLACED
355
00:19:33,565 --> 00:19:35,364
INEXPENSIVELY IN CASE OF MINOR
356
00:19:35,366 --> 00:19:37,459
DAMAGE DUE
TO A FENDER BENDER.
357
00:19:42,091 --> 00:19:44,758
TECHNICIANS EASILY INSTALL THESE
ELEMENTS OF THE BODY
358
00:19:44,760 --> 00:19:48,320
BY SNAPPING THEM INTO PLACE
WITH A FEW WELL-PLACED TAPS.
359
00:19:51,183 --> 00:19:54,643
CUSTOMERS CAN CHOOSE A
RIGHT- OR LEFT-DRIVE VEHICLE.
360
00:19:54,645 --> 00:19:56,578
HERE, A TEAM MEMBER
INSTALLS A STEERING
361
00:19:56,580 --> 00:19:58,840
WHEEL ON THE RIGHT.
362
00:19:58,842 --> 00:20:01,701
A PURPOSE-BUILT JIG HELPS HIM
GUIDE IN THE FASTENER.
363
00:20:01,703 --> 00:20:04,337
AND HE FINISHES BY WIRING
IN THE AIRBAG.
364
00:20:09,069 --> 00:20:12,328
AN AUTOMATED DELIVERY SYSTEM
SEQUENCES AND MATCHES TIRES
365
00:20:12,330 --> 00:20:15,190
TO THEIR SPECIFIED CARS.
366
00:20:15,192 --> 00:20:18,719
A SPECIALIZED DRIVER APPLIES
81 FOOT-POUNDS OF TORQUE
367
00:20:18,721 --> 00:20:22,114
TO EACH OF THE LUGS
SIMULTANEOUSLY.
368
00:20:22,116 --> 00:20:23,683
THE COMPLETED CARS UNDERGO
369
00:20:23,685 --> 00:20:26,177
AN INTENSIVE SERIES
OF QUALITY-CONTROL
370
00:20:26,179 --> 00:20:27,478
INSPECTIONS AND TESTS
371
00:20:27,480 --> 00:20:31,074
BEFORE JAGUAR CONSIDERS
THEM FINISHED.
372
00:20:31,076 --> 00:20:35,136
THE 2007 XF MODERNIZED
THE JAGUAR IMAGE.
373
00:20:35,138 --> 00:20:39,165
AND THE ALL NEW XF BRINGS THAT
MODERNIZATION A STEP FURTHER.
374
00:20:39,167 --> 00:20:42,895
THE 75-PERCENT ALUMINUM UNIBODY
MAKES IT BOTH LIGHTER
375
00:20:42,897 --> 00:20:46,432
AND MORE RIGID
THAN ITS PREDECESSOR.
376
00:20:46,434 --> 00:20:49,093
UNDER THE HOOD,
THE INNOVATIVE INGENIUM ENGINE
377
00:20:49,095 --> 00:20:51,420
MAKES IT SIMULTANEOUSLY FASTER,
378
00:20:51,422 --> 00:20:53,889
MORE POWERFUL
AND MORE EFFICIENT.
379
00:20:53,891 --> 00:20:57,318
INSIDE, LUXURY IS
EVERYWHERE ON DISPLAY,FROM
380
00:20:57,320 --> 00:20:58,719
THE VISUALLY DRAMATIC START-UP
381
00:20:58,721 --> 00:21:02,715
SEQUENCE FEATURING
TOUCH-SCREEN COMMAND OPTIONS
382
00:21:02,717 --> 00:21:04,976
TO THE FINELY CRAFTED
LEATHER UPHOLSTERY OF
383
00:21:04,978 --> 00:21:08,638
THE STEERING WHEEL,
DASHBOARD, AND SEATS.
384
00:21:08,640 --> 00:21:12,401
THE XF IS BUILT TO SUPERIOR
PERFORMANCE STANDARDS.
385
00:21:12,403 --> 00:21:15,863
CUSTOMERS CAN OPT FOR ALL-WHEEL
DRIVE WITH INTELLIGENT DRIVELINE
386
00:21:15,865 --> 00:21:19,066
DYNAMICS, WHICH DEPLOYS
A SPECIALIZED SOFTWARE
387
00:21:19,068 --> 00:21:20,660
TO ANALYZE DRIVING CONDITIONS
388
00:21:20,662 --> 00:21:24,255
AND OPTIMIZE TRACTION
AND BALANCE.
389
00:21:24,257 --> 00:21:27,057
AS A RESULT,
THIS JAGUAR IS FAST,
390
00:21:27,059 --> 00:21:29,953
QUIET, AND SUREFOOTED
AT ALL TIMES,
391
00:21:29,955 --> 00:21:32,381
JUST LIKE ITS NAMESAKE.
30871
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